Methods of making, packaging, and delivering compressed hollow coreless reformable roll products

Abstract

A compressed hollow coreless roll of absorbent paper sheet produced by way of providing a roll of absorbent paper sheet by winding the sheet about a forming core member having a diameter in the range of 30 mm to 50 mm; removing the forming core member such that there is provided a hollow coreless roll of absorbent paper sheet with an axial cavity having a diameter in the range of 30 mm to 50 mm and compressing the hollow coreless roll such that the axial cavity is substantially collapsed. The compressed hollow coreless rolls are readily re-formed into cylindrical shape. Space-saving packages of the rolls are overwrapped with tubular polymer film to provide a flexible reconfigurable package of a series of individually encased rolls. Volume reductions of about 10 to about 20%, about 14% to about 20%, 30%, 40% and more as compared with conventional products are realized.

That which is claimed: 
     
       1. A method of making and packaging a compressed hollow coreless roll of absorbent paper sheet comprising:
 providing a roll of absorbent paper sheet by winding the sheet about a forming core member having a diameter in the range of 30 mm to 75 mm; 
 removing the forming core member such that there is provided a hollow coreless roll of absorbent paper sheet with an axial cavity having a diameter in the range of 30 mm to 75 mm; 
 compressing the hollow coreless roll with opposing forces bearing against opposing lateral surfaces of the hollow coreless roll, such that the axial cavity is substantially collapsed into an elliptical void having opposing long side walls that are planar and parallel to each other and in surface contact with one another over at least 60% of their area; and 
 packaging the compressed hollow coreless roll so that the axial cavity of the compressed hollow coreless roll is maintained in the substantially collapsed configuration. 
 
     
     
       2. The method according to  claim 1 , wherein the forming core member has a diameter of from about 35 mm to 50 mm such that the axial cavity of the roll has a diameter of from 35 mm to 50 mm prior to compression of the roll. 
     
     
       3. The method according to  claim 1 , wherein the forming core member has a diameter of from about 37.5 mm to 42.5 mm such that the axial cavity of the roll has a diameter of from 37.5 mm to 42.5 mm prior to compression of the roll. 
     
     
       4. The method according to  claim 1 , wherein the forming core member is a tubular paperboard core. 
     
     
       5. The method according to  claim 1 , wherein the compressed hollow coreless roll is overwrapped with a polymeric film in order to maintain the compressed hollow coreless roll in the substantially collapsed configuration. 
     
     
       6. The method according to  claim 1 , wherein the hollow coreless tissue roll has a diameter of from about 80 mm to 230 mm prior to compression, and a thickness, after compression such that its axial cavity is substantially collapsed, of no more than about 60% of the diameter of the roll prior to compression. 
     
     
       7. The method according to  claim 1 , wherein the hollow coreless tissue roll has a diameter of from about 80 mm to 150 mm prior to compression, and a thickness, after compression such that its axial cavity is substantially collapsed, of no more than about 50% of the diameter of the roll prior to compression. 
     
     
       8. The method according to  claim 1 , wherein the hollow coreless tissue roll has a diameter of from about 100 mm to 130 mm prior to compression and a thickness after compression such that its axial cavity is substantially collapsed, of no more than about 60% of the diameter of the roll prior to compression. 
     
     
       9. The method according to  claim 1 , wherein the hollow coreless tissue roll has a diameter of from about 100 mm to 200 mm prior to compression and a thickness after compression such that its axial cavity is substantially collapsed, of no more than about 80% of the diameter of the roll prior to compression. 
     
     
       10. The method according to  claim 1 , wherein a plurality of the compressed hollow coreless rolls are overwrapped with a polymeric film to form a package of the plurality of rolls, wherein the polymeric film is effective to maintain the axial cavities of the plurality of hollow coreless rolls in the substantially collapsed configuration. 
     
     
       11. The method according to  claim 10 , wherein the package contains a re-usable tubular dispensing core which has a diameter smaller than the forming core member upon which the roll was wound. 
     
     
       12. The method according to  claim 11 , wherein the tubular dispensing core has a diameter of from 25 mm to 32 mm. 
     
     
       13. The method according to  claim 1 , wherein either:
 the opposing forces are imposed on the hollow coreless roll by at least one piston; or 
 the opposing forces are imposed on the hollow coreless roll by a pair of opposing pistons. 
 
     
     
       14. A method of delivering absorbent paper sheets comprising:
 providing a roll of absorbent paper sheet by winding the sheet about a forming core member having a diameter in the range of 30 mm to 75 mm; 
 removing the forming core member such that there is provided a hollow coreless roll of absorbent paper sheet with an axial cavity having a diameter in the range of 30 mm to 75 mm; 
 compressing the hollow coreless roll such that the axial cavity is substantially collapsed, wherein the compressing occurs via opposing forces bearing against opposing lateral surfaces of the hollow coreless roll to produce an elliptical void having opposing long side walls that are planar and parallel to each other; 
 packaging the compressed hollow coreless roll so that the axial cavity of the compressed hollow coreless roll is maintained in a substantially collapsed configuration that has the opposing long side walls of the elliptical void in surface contact over at least 60% of their area; 
 re-forming the compressed roll by expanding the substantially collapsed axial cavity; 
 mounting the re-formed compressed roll about a spindle; and 
 dispensing absorbent sheet from the outer periphery of the re-formed roll. 
 
     
     
       15. The method according to  claim 14 , further comprising inserting a tubular dispensing core into the reformed hollow coreless roll prior to mounting the roll about the spindle wherein the tubular dispensing core has a diameter smaller than the core member upon which the roll was wound. 
     
     
       16. The method according to  claim 15 , wherein the tubular dispensing core has a diameter of from 25 mm to 32 mm. 
     
     
       17. The method according to  claim 14 , wherein the forming core member has a diameter of from about 35 mm to 55 mm such that the axial cavity of the core has a diameter of from 35 mm to 50 mm prior to compression of the roll. 
     
     
       18. The method according to  claim 14 , wherein the forming core member has a diameter of from about 37.5 mm to 42.5 mm such that the axial cavity of the core has a diameter of from 37.5 mm to 42.5 mm prior to compression of the roll. 
     
     
       19. The method according to  claim 14 , wherein the forming core member is a tubular paperboard core. 
     
     
       20. The method according to  claim 14 , wherein the hollow coreless tissue roll has a diameter of from about 80 mm to 230 mm prior to compression, and a thickness, after compression such that its axial cavity is substantially collapsed, of no more than about 60% of the diameter of the roll prior to compression. 
     
     
       21. The method according to  claim 14 , wherein the hollow coreless tissue roll has a diameter of from about 80 mm to 230 mm prior to compression, and a thickness after compression such that its axial cavity is substantially collapsed, of no more than about 50% of the diameter of the roll prior to compression. 
     
     
       22. The method according to  claim 14 , wherein the hollow coreless tissue roll has a diameter of from about 100 mm to 200 mm prior to compression and a thickness after compression such that its axial cavity is substantially collapsed of no more than about 80% of the diameter of the roll prior to compression. 
     
     
       23. The method according to  claim 14 , wherein either:
 the opposing forces are imposed on the hollow coreless roll by at least one piston; or 
 the opposing forces are imposed on the hollow coreless roll by a pair of opposing pistons.